Characterization of High-Temperature Abrasive Wear of Cold-Sprayed FeAl Intermetallic Compound Coating
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hang-Jiu Li, Hong-Tao Wang, Guan-Jun Yang, and Chong-Gao Bao (Submitted May 14, 2010; in revised form July 27, 2010) FeAl intermetallic compound coating was prepared by cold spraying using a mechanically alloyed Fe(Al) alloy powder followed by post-spray annealing at 950 °C. The high-temperature abrasive wear test was carried out for the FeAl coating at a temperature range from room temperature to 800 °C. The hightemperature abrasive wear of a heat-resistant stainless steel 2520 was performed for comparison. It was observed that the abrasive wear weight loss of FeAl coating was proportional to wear cycles in terms of sample revolutions at the tested temperatures. It was found that with the increase of the test temperature higher than 400 °C, the wear rate of cold-sprayed FeAl coating decreased with the increase of test temperature, while the wear rate of the heat-resistant steel increased significantly. The results indicate that the high-temperature abrasive wear resistance of the cold-sprayed FeAl intermetallic coating increased with the increase of the wear temperature in a temperature range from 400 to 800 °C. The wear resistance of cold-sprayed FeAl coating was higher than that of heat-resistant 2520 stainless steel under 800 °C by a factor of 3.
Keywords
abrasive and erosive wear, cold gas dynamic spraying, wear mechanisms
1. Introduction FeAl intermetallic compound is a promising structural material for several industrial applications from medium to high temperatures (Ref 1-3), due to their attractive properties such as high specific strength (strength-todensity ratio), high specific stiffness (stiffness-to-density ratio), good wear resistance, and excellent high-temperature corrosion resistance in oxidizing and sulfidizing atmospheres (Ref 4, 5). Moreover, Fe and Al, which are raw materials of FeAl phase, are relatively inexpensive, and
This article is an invited paper selected from presentations at the 2010 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray: Global Solutions for Future Applications, Proceedings of the 2010 International Thermal Spray Conference, Singapore, May 3-5, 2010, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2011. Chang-Jiu Li, Guan-Jun Yang, and Chong-Gao Bao, State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, XiÕan Jiaotong University, XiÕan 710049, Shaanxi, China; and Hong-Tao Wang, School of Mechanical and Materials Engineering, Jiujiang College, Jiujiang 332005, Jiangxi, China. Contact e-mail: [email protected]. edu.cn.
Journal of Thermal Spray Technology
the FeAl intermetallic alloy is lighter than steels or Ni-based alloys (Ref 3). Therefore, FeAl alloy is a potential alternative material for stainless steels or Ni-based superalloys in applications requiring high-temperature oxidation and sulfidation resistance, such
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